Wall construction

ABSTRACT

A kit for forming a hollow block assembly to be used to construct a wall having a corner, the kit consisting of face panels, right and left corner panels and a plurality of fasteners, each panel comprising a plurality of spaced apart flanges extending perpendicularly from and attached to each panel so that a hollow block structure is assembled when the flanges of the panels are connected together, directly or indirectly, by the fasteners, the right and left corner panels being dimensioned to interconnect at the edges thereof to form a corner section of a wall.

FIELD

The instant invention is in the field of wall construction. Morespecifically, the instant invention relates to modular panels for wallconstruction such as leave-in-place forms for poured concrete walls andmore specifically to panels used to form wall corners.

BACKGROUND OF THE INVENTION

Forms for poured concrete walls comprising interlocking hollow blocksare known, see, for example, U.S. Pat. Nos. 4,703,602; 5,086,600;5,855,102; 5,992,102 and 6,536,172. Forms for poured concrete wallscomprising modular panels are known, see, for example, U.S. Pat. Nos.4,884,382; 5,570,552; 5,983,585; 6,405,505 and especially 7,320,201.However, none of the prior art technology optimizes injection moldingtechnology for wall corner applications.

SUMMARY OF THE INVENTION

An important benefit of the instant invention is that it allows a singleuser to incorporate several phases of construction into a single phase,thereby creating a finished wall having a corner. The instant inventionis a kit for forming a hollow block assembly to be used to construct awall having a corner, the kit comprising: at least two face panels, atleast one inner left corner panel, at least one inner right cornerpanel, at least one outer left corner panel, at least one outer rightcorner panel and a plurality of fasteners, each panel comprising aplurality of spaced apart flanges extending from and attached to eachpanel so that a hollow block structure is assembled when the flanges ofthe panels are connected together, directly or indirectly, by thefasteners, wherein the panels are molded of a resin selected from thegroup consisting of a thermoplastic resin and a thermoset resin, whereinthe flanges of the panels are integrally molded with the panels, whereineach flange of the panels is perforated therethrough with a plurality ofapertures and wherein each fastener is a snap-lock strap molded of aresin selected from the group consisting of a thermoplastic resin and athermoset resin and comprising projections therefrom molded integrallytherewith, the projections dimensioned to be an interference fit whenpressed through an aperture of a flange so that a hollow block structureis assembled when the projections of the straps are pressed through theapertures of the flanges of the panels, each left corner panel having aleft corner edge, each right corner panel having a right corner edge,the left and right corner edges dimensioned to interconnect so that ahollow block structure having a corner is assembled when the projectionsof the straps are pressed through the apertures of the flanges of theface and corner panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective rear view of a face panel of the prior artshowing four flanges extending therefrom;

FIG. 2 is a perspective front view of a face panel of the prior art;

FIG. 3 is a perspective view of a snap-strap of the prior art;

FIG. 4 is a top view of the snap-strap of FIG. 3;

FIG. 5 is a side view of the snap-strap of FIG. 3;

FIG. 6 is a an end view of a pair of face panels of FIG. 1 attached toeach other using snap-straps as shown in FIG. 3;

FIG. 7 is an end view from the other end of the assembly shown in FIG.6;

FIG. 8 is a top view of two of the assemblies of FIGS. 6 and 7 engagedend to end and also showing a number of insulation panels;

FIG. 9 is a perspective view of a prior art base-plate system for usewith the block assembly of the prior art;

FIG. 10 is a perspective view of a prior art half block outer corner foruse with the block assembly of the prior art;

FIG. 11 is a perspective view of a prior art full block outer corner foruse with the block assembly of the prior art; X

FIG. 12 is a perspective view of a prior art inner corner for use withthe block assembly of the prior art;

FIG. 13 is a perspective view of a prior art end cap for use with theblock assembly of the prior art;

FIG. 14 is a perspective view of a prior art top cap for use with theblock assembly of the prior art;

FIG. 15 is a perspective view of a prior art perforated strap for use inthe prior art;

FIG. 16 is a perspective view of a press-fit fastener for use in theprior art;

FIG. 17 is a perspective rear view of another prior art face panel ofthe prior art showing four flanges extending therefrom;

FIG. 18 is an end view of a pair of the face panels of FIG. 17 attachedto each other using steel concrete reinforcing rods;

FIG. 19 is a perspective view of a preferred inner right corner panel ofthe instant invention;

FIG. 20 is a perspective view of a preferred inner left corner panel ofthe instant invention;

FIG. 21 is a perspective view of the panels of FIGS. 19 and 20 connectedtogether to form a preferred inner corner of the instant invention;

FIG. 22 is a perspective view of a preferred outer left corner panel ofthe instant invention;

FIG. 23 is a perspective view of a preferred outer right corner panel ofthe instant invention;

FIG. 24 is a perspective view of the panels of FIGS. 22 and 23 connectedtogether to form a preferred outer corner of the instant invention;

FIG. 25 is a perspective view of a face panel of the instant inventionhaving aligning tabs on each side thereof;

FIG. 26 is a perspective view of a preferred snap-strap of the instantinvention; and

FIG. 27 is a side view of the snap-strap of FIG. 26.

DETAILED DESCRIPTION

Referring now to FIG. 1, therein is shown a perspective rear view of apreferred face panel 10 of the prior art molded of a thermoplasticpolymer or resin such as, without limitation thereto, impact modifiedpolystyrene, polyethylene, PVC, PVC structural foam or a thermoset resinsuch as, without limitation thereto, a phenol-formaldehyde resin. Theface panel 10 has four flanges 11 extending perpendicularly therefromand integrally molded therewith. Each flange 11 is perforatedtherethrough with a plurality of apertures 12. One side of the panel 10has an alignment tab 13. Referring now to FIG. 2, therein is shown aperspective front view of the face panel of 10 of FIG. 1. It should beunderstood that the face panels of the prior art can be made of anysuitable material such as, without limitation thereto, galvanized sheetsteel, sheet aluminum and wood or wood compositions such as chip board.Preferably, the face panels of the prior art are made of thermoplasticor thermoset resins. It should be understood that when the panels and/orfasteners of the prior art are made of molded thermoplastic, thenrecycled thermoplastic can be used to help advance the quality of theenvironment.

Referring now to FIG. 3, therein is shown a perspective view of apreferred “snap-strap” 17 of the prior art molded of a thermoplasticpolymer or resin such as, without limitation thereto, a plasticizedpolyvinyl chloride material or a thermoset resin such as, withoutlimitation thereto, a polyurethane resin. The strap 17 comprisesprojections 18 therefrom molded integrally therewith. The projections 18are dimensioned to be an interference fit when pressed through anaperture 12 of a flange 11 of the face panel 10 shown in FIG. 1. FIG. 4shows a top view of the snap-strap 17 of FIG. 3. FIG. 5 shows a sideview of the snap-strap 17 of FIG. 3.

Referring now to FIG. 6, therein is shown an end view of a hollow blockstructure 19 assembled when the projections 18 of the snap-straps 17 arepressed through the apertures of the flanges 11 of the face panels 10.Referring now to FIG. 7, therein is shown an end view of the hollowblock structure 19 of FIG. 6 from the other end. In use, a number ofblock structures 19 are arrayed in a horizontal course with the sidealigning tabs 13 fitted under the adjoining face panel. Then anotherhorizontal course of block structures 19 is pressed in staggered fashionabove the first course so that locking tabs 15 (also called snap buttonsherein) of the face panels 10 engage with the holes or openings 16 inthe upper aligning tabs 14. Then, if desired, additional horizontalcourses of block structures 19 are laid until the wall or footing formis as high as desired. Reinforcing steel rods can, of course, beinserted as desired as the courses are laid. If larger panels are used,then a wall can be formed from one course of the block structures of theprior art.

Referring again to FIG. 5, it will be noted that the preferred shape ofthe projections 18 is in the form of a chevron in cross-section.However, it should be understood that other shapes (such as a spheroid)can be used if desired. The outside diameter of the projections 18 issomewhat larger than inside diameter of the apertures 12 so that theprojections 18 are an interference fit when the projections 18 arepressed through the apertures 12 to assemble the block structure 19 ofFIG. 6.

Referring again to FIG. 1, it is preferable to mold four flanges 11 fromthe face plate 10 as shown so that half or even quarter blocks can beassembled by sawing the face plate 10 in half or in quarters. Althoughthe block assembly 19 of FIGS. 6 and 7 is assembled from identical faceplates 10, it should be understood that a face plate which is a mirrorimage of the face plate 10 is preferred so that the side aligning tabsof a block assembly face the same direction.

Referring now to FIG. 8, therein is shown a top view of two of theassemblies 19 of FIGS. 6 and 7 engaged end to end. Closed cellpolystyrene foam thermal-insulation panels 20 are then inserted as shownand are highly preferred as providing not only thermal insulation butadded strength to the form to withstand the hydraulic pressure of thefluid concrete poured into the form before the fluid concrete cures.And, if larger panels are used, then an insulated wall, insulated with,for example and without limitation thereto, fiberglass or blown-incellulose insulation, can be formed from one course of the blockstructures of the prior art even if the wall is not filled withconcrete.

The exterior and/or interior of the face panels of the prior art arepreferably “finish-faced”. The term “finish-faced” means an externalsurface not requiring further finishing. Such an external surface couldbe, for example and without limitation thereto, a stucco type of surfaceor vertical lines that could-disguise, if desired, the vertical jointsof the wall. The face panels can, of course, be molded of a coloredthermoplastic or thermoset polymer or resin so that the finished walldoes not require painting. The prior art can be used, of course, to makefootings, foundation walls and walls above grade.

An important benefit of the prior art is that by the use of snap-strapsof different lengths, walls and the like can be constructed of differentthicknesses. The use of relatively long face panels of appropriatedesign permits the ready adaptation of the prior art to the constructionof curved walls.

Referring now to FIG. 9, therein is shown a base-plate system 21 for usewith the hollow blocks of the prior art. The base-plate system 21consists of a front face 22 and a rear face 23 connected by snap straps24 (all of which are preferably injection molded of a thermoplastic orthermoset resin). In use, the base plate system 21 can be, for example,grouted to a footing. The locking tabs (15 of FIG. 6) of the firstcourse of hollow blocks of the prior art are then located over andpressed into the holes 25 in the front and rear faces 22 and 23.Alternatively, the first course of hollow blocks of the prior art cansimply be grouted to the footing.

Referring now to FIG. 10, therein is shown a perspective view of apreferred half block outer corner 26 for use with the hollow blocks ofthe prior art which is preferably also molded of a thermoplastic orthermoset resin. Referring now to FIG. 11, therein is shown aperspective view of a preferred full block outer corner 27 for use withthe hollow blocks of the prior art which is preferably also molded of athermoplastic or thermoset resin. Referring now to FIG. 12, therein isshown a perspective view of a preferred full inner corner 28 for usewith the hollow blocks of the prior art which is preferably also moldedof a thermoplastic or thermoset resin. Referring now to FIG. 13, thereinis shown a perspective view of a preferred end cap 29 for use with thehollow blocks of the prior art (which is preferably also molded of athermoplastic or thermoset resin) if it is desired to end a wall orfooting. The end cap 29 can be held in place by screws, not shown,driven through the end of a hollow block to engage the tabs 29 a of theend cap 29. Referring now to FIG. 14, therein is shown a perspectiveview of a preferred top cap 29 for use with the hollow blocks of theprior art (which is preferably also molded of a thermoplastic orthermoset resin) if it is desired to finish the top of a wall orfooting. The top cap 29 preferably has locking tabs (like the lockingtabs 15 of FIG. 1) molded with the skirt 30 a of the top cap 29 toengage with the holes in the aligning tabs of the hollow block of theprior art.

The snap strap 17 of FIG. 3 is an example of a fastener for the indirectconnection of a flange of one face panel to a flange of another facepanel. Referring now to FIG. 15, therein is shown a strap 31 perforatedtherethrough with apertures 32. Of course, the flanges of the faceplates discussed above can be molded or otherwise formed to haveprojections which are dimensioned to be an interference fit when pressedthrough the apertures 32 of the strap 31. And, of course, the flanges ofone panel can have apertures while the corresponding flanges of theother panel can be molded or otherwise formed to have projections whichare dimensioned to be an interference fit when pressed through saidapertures. However, referring now to FIG. 16, therein is shown a “X-MassTree Clip” fastener” 33 available from K-International of Gurnee, Ill.Thirty two of such fasteners 33 can be used to attach one face plate 10of FIG. 1 to another face plate 10 of FIG. 1 by pressing said fastenersthrough the apertures 32 of the strap 31 of FIG. 15 and the apertures 12of the face plate 10 of FIG. 1 to produce a block assembly similar tothe block assembly 19 of FIG. 6. The outside diameter of the chevrons 34of the fastener 33 are dimensioned to be an interference fit in theapertures 32 and 12. A simple length of wire can be used as a fastenerto attach one panel to another panel by passing the wire through theapertures of the flanges of the panels and bending the wire around theapertures. The fastener 33 is but one example of a whole family ofpress-fit fasteners which are commercially available. For example, andwithout limitation thereto, said K-International offers snap rivets,Viking clips, quick grip fasteners, dart clips, ratchet rivet fastenersand arrow clips. And, of course, conventional fasteners such as nuts andbolts can also be used.

Referring now to FIG. 17, therein is shown a perspective rear view of apreferred face panel 35 of the prior art molded of a thermoplasticpolymer or resin such as, without limitation thereto, impact modifiedpolystyrene, polyethylene or a thermoset resin such as, withoutlimitation thereto, a phenol-formaldehyde resin. The face panel 35 hasfour flanges 40 extending perpendicularly therefrom and integrallymolded therewith. Each flange 40 is perforated therethrough with aplurality of apertures 41. Each panel 35 has side aligning tabs 36,upper aligning tabs 39, holes 38 and locking tabs 37. Two panels 35 canbe joined together by pressing fasteners 33 of FIG. 16 through theapertures 41 of each face plate 35. Alternatively, any desired fastenercan be used for this purpose.

Referring now to FIG. 18, when it is desired to produce a pouredreinforced concrete wall, a preferred fastener for connecting the facepanels together is a number of steel concrete reinforcing rods 42positioned in the apertures 41 of the panels 35 of FIG. 17. Preferably,the outside diameter of the rods 42 is smaller than the inside diameterof the apertures 41.

Referring again to FIGS. 10-12, the molds needed to mold such prior artcorner panels have been found to be more complex than desired. Referringnow to FIGS. 19-24, therein is shown a preferred means of forming a wallhaving a corner according to the instant invention. The molds needed tomold the panels shown in FIGS. 19-24 are less complex than the moldsneeded to mold the panels shown in FIGS. 10-12. Otherwise, the teachingsabove regarding the system shown in FIGS. 1-18 apply to the panels andstraps of FIGS. 19-24.

Referring now to FIG. 19, therein is shown a perspective view of apreferred inner right corner panel 43 of the instant invention. In mostrespects the panel 43 is the similar to the panel 10 of FIG. 1. Howeverthe panel 43 has perforated projections 44 attached to the panel 43 atthe inside left edge thereof Referring now to FIG. 20, therein is showna perspective view of a preferred inner left corner panel 46 of theinstant invention. In most respects the panel 46 is the similar to thepanel 10 of FIG. 1. However the panel 46 has snap-lock projections 47attached to the panel 46 at the inside right edge thereof Referring nowto FIG. 21, therein is shown a perspective view of the panels of FIGS.19 and 20 connected together to form a preferred inner corner of theinstant invention. The perforated projections 44 and snap-lockprojections 47 of FIGS. 19 and 20 are not critical in the instantinvention and any suitable substitute joining system can be used (such asingle hinge pin or a dovetail joint) as long as the panels 43 and 46interconnect at the appropriate edges thereof.

Referring now to FIG. 22, therein is shown a perspective view of apreferred outer left corner panel 49 of the instant invention. In mostrespects the panel 49 is the similar to the panel 10 of FIG. 1. Howeverthe panel 49 has perforated projections 50 attached to the panel 49 atthe inside right edge thereof. Referring now to FIG. 23, therein isshown a perspective view of a preferred outer right corner panel 51 ofthe instant invention. In most respects the panel 51 is the similar tothe panel 10 of FIG. 1. However the panel 51 has snap-lock projections52 attached to the panel 51 at the inside left edge thereof. Referringnow to FIG. 24, therein is shown a perspective view of the panels ofFIGS. 22 and 23 connected together to form a preferred outer corner ofthe instant invention. The perforated projections 50 and snap-lockprojections 52 of FIGS. 22 and 23 are not critical in the instantinvention and any suitable substitute joining system can be used (such asingle hinge pin or a dovetail joint) as long as the panels 43 and 46interconnect at the appropriate edges thereof.

Referring now to FIG. 25, therein is shown a perspective view of a facepanel 54 of the instant invention. The face panel 54 is similar in mostrespects to the face panel 10 of FIG. 1 but the face panel 54 hasaligning tabs 55 and 56 on each side thereof The face panel 54 hasutility when used with the assemblies shown in FIGS. 21 and 24 to form awall having a corner.

Referring now to FIG. 26, therein is shown a perspective view of apreferred snap-strap 57 of the instant invention having molded in placeflexible projections 58 and a molded reinforcement section 59. Referringnow to FIG. 27, therein is shown a side view of the snap-strap of FIG.26.

CONCLUSION

While the instant invention has been described above according to itspreferred embodiments, it can be modified within the spirit and scope ofthis disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the instant invention using thegeneral principles disclosed herein. Further, the instant application isintended to cover such departures from the present disclosure as comewithin the known or customary practice in the art to which thisinvention pertains and which fall within the limits of the followingclaims.

1. A kit for forming a hollow block assembly to be used to construct awall having a corner, the kit comprising: at least two face panels, atleast one inner left corner panel, at least one inner right cornerpanel, at least one outer left corner panel, at least one outer rightcorner panel and a plurality of fasteners, each panel comprising aplurality of spaced apart flanges extending from and attached to eachpanel so that a hollow block structure is assembled when the flanges ofthe panels are connected together, directly or indirectly, by thefasteners, wherein the panels are molded of a resin selected from thegroup consisting of a thermoplastic resin and a thermoset resin, whereinthe flanges of the panels are integrally molded with the panels, whereineach flange of the panels is perforated therethrough with a plurality ofapertures and wherein each fastener is a snap-lock strap molded of aresin selected from the group consisting of a thermoplastic resin and athermoset resin and comprising projections therefrom molded integrallytherewith, the projections dimensioned to be an interference fit whenpressed through an aperture of a flange so that a hollow block structureis assembled when the projections of the straps are pressed through theapertures of the flanges of the panels, each left corner panel having aleft corner edge, each right corner panel having a right corner edge,the left and right corner edges dimensioned to interconnect so that ahollow block structure having a corner is assembled when the projectionsof the straps are pressed through the apertures of the flanges of theface and corner panels.